Automated construction robot systems and methods

ABSTRACT

An automated construction robot system includes: a mobile base assembly configured to be displaceable within the work area; a head assembly configured to process a work surface; an arm assembly configured to moveably-couple the head assembly and the mobile base assembly and controllably-displace the head assembly with respect to the work surface; a machine vision system configured to scan a target area and generate target area information; and a computational system configured to: process the target area information to identify a surface defect, generate one or more remedial instructions based, at least in part, upon the surface defect identified, and manipulate one or more of the mobile base assembly, the head assembly and the arm assembly based, at least in part, upon the one or more remedial instructions.

RELATED APPLICATION(S)

This application claims the benefit of the following U.S. ProvisionalApplication Nos.: 62/723,137, filed on 27 Aug. 2018 and 62/851,336,filed on 22 May 2019, their entire contents of which are hereinincorporated by reference.

TECHNICAL FIELD

This disclosure relates to automated robot systems and, moreparticularly, to automated robot systems for use within the buildingtrades and the construction industry.

BACKGROUND

The robotics industry is enabling the automation of tedious and/orrepetitive tasks. Numerous industries (such as the consumer electronicsindustry and the automotive industry) make extensive use of robotics.And through the use of robotics, a higher level of worker safety may berealized (as robots may be utilized in dangerous environments). Further,a higher level of predictability may be achieved, as robots maycontinuously and repeatedly perform that same task with a high level ofconsistency.

Unfortunately, certain industries have been slower to adopt robotictechnology. For example, the building trades and the constructionindustry have been slower to utilizes such technology due to themobility requirements of the robots and the transient nature of the joblocations.

SUMMARY OF DISCLOSURE Concept 3

In one implementation, an automated construction robot system includes:a mobile base assembly configured to be displaceable within the workarea; a head assembly configured to process a work surface; an armassembly configured to moveably-couple the head assembly and the mobilebase assembly and controllably-displace the head assembly with respectto the work surface; a machine vision system configured to scan a targetarea and generate target area information; and a computational systemconfigured to: process the target area information to identify a surfacedefect, generate one or more remedial instructions based, at least inpart, upon the surface defect identified, and manipulate one or more ofthe mobile base assembly, the head assembly and the arm assembly based,at least in part, upon the one or more remedial instructions.

One or more of the following features may be included. Manipulating oneor more of the mobile base assembly, the head assembly and the armassembly based, at least in part, upon the one or more remedialinstructions may include one or more of: utilizing the head assembly tosand the surface defect identified; utilizing the head assembly to applyjoint compound to the surface defect identified; utilizing the headassembly to apply joint tape to the surface defect identified; utilizingthe head assembly to set a protruding drywall screw within the surfacedefect identified; and utilizing the head assembly to set a protrudingnail within the surface defect identified. The surface defect identifiedmay include one or more of: a high spot within the work surface; a lowspot within the work surface; a crack within the work surface; a holewithin the work surface; a protruding screw within the work surface; anda protruding nail within the work surface. The computational system maybe further configured to: manipulate one or more of the mobile baseassembly, the head assembly and the arm assembly to apply a coatingmaterial to the work surface via the head assembly. Manipulating one ormore of the mobile base assembly, the head assembly and the arm assemblyto apply a coating material to the work surface via the head assemblymay include one or more of: controlling the movement of the mobile baseassembly within a work area; extending/retracting the arm assembly withrespect to the mobile base assembly; controlling the location of thehead assembly with respect to the work surface and/or the mobile baseassembly; controlling the velocity of the head assembly with respect tothe work surface and/or the mobile base assembly; rotating the headassembly with respect to the work surface; and controlling the angle ofincidence of the head assembly with respect to the work surface.Manipulating one or more of the mobile base assembly, the head assemblyand the arm assembly to apply a coating material to the work surface viathe head assembly may include one or more of: controlling a spray fanwidth of the coating material applied to the work surface via the headassembly; controlling the volume of the coating material provided to thehead assembly; and controlling the pressure of the coating materialprovided to the head assembly. The arm assembly may include: a wristassembly configured to enable the rotation of the head assembly withrespect to the arm assembly. The arm assembly may include: a rotationassembly configured to enable the rotation of the arm assembly withrespect to the mobile base assembly. The automated construction robotsystem may include a plurality of automated construction robots. Theplurality of automated construction robots may include: a primaryconstruction robot; and a scout construction robot. The scoutconstruction robot may be configured to scan the target area andgenerate the target area information.

In another implementation, a computer-implemented method is executed onan automated construction robot system and includes: processing targetarea information to identify a surface defect; generating one or moreremedial instructions based, at least in part, upon the surface defectidentified; and manipulating one or more of a mobile base assembly, ahead assembly and an arm assembly based, at least in part, upon the oneor more remedial instructions; wherein: the mobile base assembly isconfigured to be displaceable within a work area, the head assembly isconfigured to process the work surface, and the arm assembly isconfigured to moveably-couple the head assembly and the mobile baseassembly and controllably-displace the head assembly with respect to thework surface.

One or more of the following features may be included. Manipulating oneor more of the mobile base assembly, the head assembly and the armassembly based, at least in part, upon the one or more remedialinstructions may include one or more of: utilizing the head assembly tosand the surface defect identified; utilizing the head assembly to applyjoint compound to the surface defect identified; utilizing the headassembly to apply joint tape to the surface defect identified; utilizingthe head assembly to set a protruding drywall screw within the surfacedefect identified; and utilizing the head assembly to set a protrudingnail within the surface defect identified. The surface defect identifiedmay include one or more of: a high spot within the work surface; a lowspot within the work surface; a crack within the work surface; a holewithin the work surface; a protruding screw within the work surface; anda protruding nail within the work surface. The arm assembly may include:a wrist assembly configured to enable the rotation of the head assemblywith respect to the arm assembly. The arm assembly may include: arotation assembly configured to enable the rotation of the arm assemblywith respect to the mobile base assembly.

In another implementation, a computer program product resides on acomputer readable medium having a plurality of instructions storedthereon. When executed by an automated construction robot system, theseinstructions cause the automated construction robot system to performoperations including: processing target area information to identify asurface defect; generating one or more remedial instructions based, atleast in part, upon the surface defect identified; and manipulating oneor more of a mobile base assembly, a head assembly and an arm assemblybased, at least in part, upon the one or more remedial instructions;wherein: the mobile base assembly is configured to be displaceablewithin a work area, the head assembly is configured to process the worksurface, and the arm assembly is configured to moveably-couple the headassembly and the mobile base assembly and controllably-displace the headassembly with respect to the work surface.

One or more of the following features may be included. Manipulating oneor more of the mobile base assembly, the head assembly and the armassembly based, at least in part, upon the one or more remedialinstructions may include one or more of: utilizing the head assembly tosand the surface defect identified; utilizing the head assembly to applyjoint compound to the surface defect identified; utilizing the headassembly to apply joint tape to the surface defect identified; utilizingthe head assembly to set a protruding drywall screw within the surfacedefect identified; and utilizing the head assembly to set a protrudingnail within the surface defect identified. The surface defect identifiedmay include one or more of: a high spot within the work surface; a lowspot within the work surface; a crack within the work surface; a holewithin the work surface; a protruding screw within the work surface; anda protruding nail within the work surface. The arm assembly may include:a wrist assembly configured to enable the rotation of the head assemblywith respect to the arm assembly. The arm assembly may include: arotation assembly configured to enable the rotation of the arm assemblywith respect to the mobile base assembly.

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other features andadvantages will become apparent from the description, the drawings, andthe claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1E are diagrammatic views of an automated construction robotsystem according to an embodiment of the present disclosure;

FIG. 2 is a flowchart of an automated construction robot processexecuted by the automated construction robot system of FIGS. 1A-1Eaccording to an embodiment of the present disclosure;

FIG. 3 is a diagrammatic detail view of the head assembly of FIGS. 1A-1Eaccording to an embodiment of the present disclosure;

FIG. 4 is a another flowchart of an automated construction robot processexecuted by the automated construction robot system of FIGS. 1A-1Eaccording to an embodiment of the present disclosure;

FIG. 5 is a another flowchart of an automated construction robot processexecuted by the automated construction robot system of FIGS. 1A-1Eaccording to an embodiment of the present disclosure;

FIG. 6 is a another flowchart of an automated construction robot processexecuted by the automated construction robot system of FIGS. 1A-1Eaccording to an embodiment of the present disclosure;

FIG. 7 is a another flowchart of an automated construction robot processexecuted by the automated construction robot system of FIGS. 1A-1Eaccording to an embodiment of the present disclosure;

FIG. 8 is a another flowchart of an automated construction robot processexecuted by the automated construction robot system of FIGS. 1A-1Eaccording to an embodiment of the present disclosure; and

FIG. 9 is a diagrammatic detail view of a variable-duty-cyclemicrocontroller assembly of the automated construction robot system ofFIGS. 1A-1E according to an embodiment of the present disclosure.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS System Overview

Referring to FIGS. 1A-1E, there is shown automated construction robotsystem 10, wherein automated construction robot system 10 may includemobile base assembly 12 configured to be displaceable within work area14. Examples of mobile base assembly 12 may include any kind of baseassembly that would allow for the movement of automated constructionrobot system 10 within work area 14. One example of mobile base assembly12 may include but is not limited to a mobile base assembly thatincludes a plurality of wheels that allow for the movement of mobilebase assembly 12 within work area 14, wherein such a wheeled mobile baseassembly may be highly suitable for situations in which work area 14 isa smooth surface (e.g., a finished floor). Another example of mobilebase assembly 12 may include but is not limited to a mobile baseassembly that includes a plurality of tracks (not shown) that allow forthe movement of mobile base assembly 12 within work area 14, whereinsuch a tracked mobile base assembly may be highly suitable forsituations in which work area 14 is a rough surface (e.g., unevenground).

Automated construction robot system 10 may include head assembly 16configured to process work surface 18. As will be discussed below ingreater detail, examples of work surface 18 may include but are notlimited to interior walls, exterior walls, trim work, door assemblies,and window assemblies. As will also be discussed below in greaterdetail, head assembly 16 may be configured to apply a coating material(e.g., a sealer coating, a primer coating, a paint coating, a staincoating, a varnish coating, a polyurethane coating, and an epoxy-basedcoating) to work surface 18. Further and as will be discussed below ingreater detail, head assembly 16 may be configured to make repairs towork surface 18.

Automated construction robot system 10 may include arm assembly 20configured to moveably-couple head assembly 16 and mobile base assembly12 and controllably-displace head assembly 16 with respect to worksurface 18. Examples of arm assembly 20 may include anyhydraulically-actuated, pneumatically-actuated, and/orelectrically-actuated, computer-controllable arm assembly that may beconfigured to movably-couple head assembly 16 and mobile base assembly12.

Arm assembly 20 may include wrist assembly 22 configured to enable therotation of head assembly 16 with respect to arm assembly 20. Examplesof wrist assembly 22 may include any assembly that allows for therotation of head assembly 16 about an X-axis, a Y-axis, and/or a Z-axis.

Arm assembly 20 may include rotation assembly 24 configured to enablethe rotation of arm assembly 20 with respect to mobile base assembly 12.Examples of rotation assembly 24 may include any assembly that allowsfor the rotation of arm assembly 20 about a Z-axis.

Automated construction robot system 10 may include machine vision system26 configured to scan a target area (e.g., target area 28) and generatetarget area information 30. Examples of machine vision system 26 mayinclude but are not limited to one or more of an RGB imaging system, aninfrared imaging system, an ultraviolet imaging system, a laser imagingsystem, a SONAR imaging system, a RADAR imaging system, and a thermalimaging system. Examples of target area information 30 may include butis not limited to any analog and/or digital representation of targetarea 28 that enables (as will be discussed below in greater detail)automated construction robot system 10 to process target area 28 andcontrol one or more of mobile base assembly 12, head assembly 16, armassembly 20, wrist assembly 22, rotation assembly 24 and machine visionsystem 26.

As will be disclosed below in greater detail, automated constructionrobot system 10 may include computational system 32 configured toexecute automated construction robot process 34 and enable theinterfacing with (and controlling of) one or more of mobile baseassembly 12, head assembly 16, arm assembly 20, wrist assembly 22,rotation assembly 24 and machine vision system 26.

The instruction sets and subroutines of automated construction robotprocess 34, which may be stored on storage device 36 coupled tocomputational system 32, may be executed by one or more processors (notshown) and one or more memory architectures (not shown) included withincomputational system 32. Examples of storage device 36 may include butare not limited to: a hard disk drive; a RAID device; a random accessmemory (RAM); a read-only memory (ROM); and all forms of flash memorystorage devices.

Automated construction robot system 10 may be coupled to network 40 toe.g., allow automated construction robot system 10 to be controlled byuser 42, allow for the receiving of instructions by automatedconstruction robot system 10, and allow for the providing of data (e.g.,status data, progress data, defect data, etc.) to user 42. For example,automated construction robot system 10 may be configured to bewirelessly coupled to access point 44 via wireless communication channel46 established between automated construction robot system 10 and accesspoint 44.

Examples of network 40 may include but are not limited to any type ofwired or wireless network (e.g., a local area network; a wide areanetwork; a wifi network, a cellular network, the internet and/or anintranet). Examples of access point 44 may include, but are not limitedto, an IEEE 802.11a/b/g/n access point, a Wi-Fi access point, and/or aBluetooth access point that is capable of establishing wirelesscommunication channel 46 between automated construction robot system 10and access point 44.

As is known in the art, IEEE 802.11x specifications may use Ethernetprotocol and carrier sense multiple access with collision avoidance(i.e., CSMA/CA) for path sharing. The various 802.11x specifications mayuse phase-shift keying (i.e., PSK) modulation or complementary codekeying (i.e., CCK) modulation, for example. As is known in the art,Bluetooth is a telecommunications industry specification that allowse.g., mobile phones, computers, and personal digital assistants to beinterconnected using a short-range wireless connection.

Concept 1 (Automated Application)

As discussed above, automated construction robot system 10 may includecomputational system 32 configured to execute automated constructionrobot process 34 and enable the interfacing with (and controlling of)one or more of mobile base assembly 12, head assembly 16, arm assembly20, wrist assembly 22, rotation assembly 24 and machine vision system26.

Accordingly and referring also to FIG. 2, automated construction robotprocess 34 may be configured to manipulate 100 one or more of mobilebase assembly 12, head assembly 16 and arm assembly 20 to apply coatingmaterial 48 (e.g., a sealer coating, a primer coating, a paint coating,a stain coating, a varnish coating, a polyurethane coating, and anepoxy-based coating) to work surface 18 via head assembly 16.

Coating material 48 may be locally or remotely provided. For example,automated construction robot system 10 may include an internal chamber(e.g., internal chamber 50) within which coating material 48 may bestored. For example, internal chamber 50 may be configured so that user42 of automated construction robot system 10 may fill internal chamber50 with coating material 48 from e.g., a supply bucket/container.Alternatively, automated construction robot system 10 may be configuredto receive coating material 48 from an external container. For example,supply line assembly 52 may be configured to be coupled to externalcontainer 54 (that may contain coating material 48). Additional externalcontainers (e.g., flushing fluid supply container 56 and flushing fluidreceipt container 58) may be utilized by automated construction robotsystem 10 to effectuate the cleaning of the same (wherein supply lineassembly 52 may be placed into flushing fluid supply container 56 andhead assembly 16 may be positioned to discharge into flushing fluidreceipt container 58).

When manipulating 100 one or more of mobile base assembly 12, headassembly 16 and arm assembly 20 to apply coating material 48 to worksurface 18 via head assembly 16, automated construction robot process 34perform one or more of the following operations:

-   -   Controlling 102 the movement of mobile base assembly 12 within        work area 14. For example, automated construction robot process        34 may be configured to control 102 the movement of mobile base        assembly 12 in the X-axis (perpendicular to work surface 18)        and/or Y-axis (parallel to work surface 18). Specifically,        automated construction robot process 34 may be configured to        repeatedly move mobile base assembly 12 along the Y-axis to        allow for the continued application of coating material 48 to        work surface 18.    -   Extending/retracting 104 arm assembly 20 with respect to mobile        base assembly 12. For example, automated construction robot        process 34 may be configured to extend/retract 104 arm assembly        20, resulting in the displacement of head assembly 16 in the        X-axis, Y-axis and/or Z-axis and the positioning of head        assembly 16 with respect to work surface 18.    -   Controlling 106 the location of head assembly 16 with respect to        work surface 18 and/or mobile base assembly 12. For example,        automated construction robot process 34 may be configured to        control arm assembly 20, wrist assembly 22 and/or rotation        assembly 24 to control 106 the location of head assembly 16 with        respect to work surface 18 and/or mobile base assembly 12.        Specially, automated construction robot process 34 may control        106 the location of head assembly 16 to e.g., move head assembly        16 along the Z-axis and apply coating material 48 in vertical        stripes along work surface 18. Further, automated construction        robot process 34 may control 106 the location of head assembly        16 to e.g., move head assembly 16 along the Y-axis and apply        coating material 48 in horizontal stripes along work surface 18.        Additionally, automated construction robot process 34 may        control 106 the location of head assembly 16 to e.g., move head        assembly 16 along the X-axis (i.e., toward and away from work        surface 18) to vary the width of the stripe of coating material        48 applied to work surface 18.    -   Controlling 108 the velocity of head assembly 16 with respect to        work surface 18 and/or mobile base assembly 12. For example,        automated construction robot process 34 may be configured to        control the rate at which arm assembly 20 moves, control the        rate at which wrist assembly 22 moves and/or control the rate at        which rotation assembly 24 moves to control 108 the velocity of        head assembly 16 with respect to work surface 18 and/or mobile        base assembly 12. Specifically, by controlling 108 the velocity        of head assembly 16 (with respect to work surface 18), the        thickness of coating material 48 applied to work surface 18 may        be regulated.    -   Rotating 110 head assembly 16 with respect to work surface 18.        For example, automated construction robot process 34 may be        configured to control wrist assembly 22, thus enabling the        rotation of head assembly 16 about an X-axis, a Y-axis, and/or a        Z-axis. For example, if head assembly 16 is positioned to        generate a horizontal spray fan (as shown in FIGS. 1A-1B) when        applying coating material 48, head assembly 16 may be displaced        in the Z-axis to generate a vertical stripe of coating material        48. Alternatively, automated construction robot process 34 may        rotate 110 head assembly 16 ninety degrees about the X-axis,        thus positioning head assembly 16 to generate a vertical spray        fan (not shown) when applying coating material 48, thus allowing        head assembly 16 to be displaced in the Y-axis to generate a        horizontal stripe of coating material 48.    -   Controlling 112 the angle of incidence (Θ) of head assembly 16        with respect to work surface 18. Referring also to FIG. 3, the        angle of incidence (Θ) is the angle between a ray incident on a        surface (e.g., work surface 18) and the line perpendicular to        the surface at the point of incidence. Accordingly and when        spray fan 150 is positioned perpendicular to work surface 18 (as        shown in solid lines), the angle of incidence (Θ) is 90 degrees.        This may result in a decrease in the crispness of the edges 152,        154 of coating material 48 applied to work surface 18. However,        rotating spray fan 150 about pivot point 156 included within        wrist assembly 22 in a clockwise/counterclockwise direction may        result in a decrease in the angle of incidence (Θ) and an        increase in the crispness of: the edge 152 (when rotating in a        clockwise direction); and edge 154 (when rotating in a        counterclockwise direction).    -   Controlling 114 a spray fan width (e.g., spray fan width 158) of        coating material 48 applied to work surface 18 via head assembly        16. For example, nozzle assembly 160 of head assembly 16 may be        a variable geometry nozzle assembly that is configurable to        allow for adjustment of spray fan width 158 (thus allowing for        the increase/decrease of spray fan width 158).    -   Controlling 116 the volume of coating material 48 provided to        head assembly 16. For example, supply line assembly 52 may be        utilized to receive coating material 48 from a coating supply        system (e.g., internal chamber 50 or external container 54).        Pump assembly 162 may be utilized to pressurize coating material        48 (drawn from internal chamber 50/external container 54) and        variable-duty-cycle microcontroller assembly 164 may be utilized        to control 116 the volume of coating material 48 provided to        head assembly 16, wherein pump assembly 162 and/or        variable-duty-cycle microcontroller assembly 164 may be        controllable by automated construction robot process 34 (as will        be discussed below in greater detail).    -   Controlling 118 the pressure of coating material 48 provided to        head assembly 16. For example, supply line assembly 52 may be        utilized to receive coating material 48 from a coating supply        system (e.g., internal chamber 50 or external container 54).        Pump assembly 162 may be utilized to pressurize coating material        48 (drawn from internal chamber 50/external container 54) and        variable-duty-cycle microcontroller assembly 164 may be utilized        to control 118 the pressure of coating material 48 provided to        head assembly 16, wherein pump assembly 162 and/or        variable-duty-cycle microcontroller assembly 164 may be        controllable by automated construction robot process 34 (as will        be discussed below in greater detail).

Concept 2 (Generation of a Coating Plan)

As discussed above, automated construction robot system 10 may includecomputational system 32 configured to execute automated constructionrobot process 34 and enable the interfacing with (and controlling of)one or more of mobile base assembly 12, head assembly 16, arm assembly20, wrist assembly 22, rotation assembly 24 and machine vision system26.

Further and as discussed above, automated construction robot system 10may include machine vision system 26 configured to scan a target area(e.g., target area 28) and generate target area information 30. Whenscanning target area 28 to generate target area information 30,automated construction robot process 34 may manipulate and maneuverautomated construction robot system 10 (generally) and mobile baseassembly 12 (specifically) so that machine vision system 26 may scan theentirety of work surface 18 to generate target area information 30.

Referring also to FIG. 4, automated construction robot process 34 may beconfigured to process 200 target area information 30 to define work areacoating plan 60. For this example, assume that work surface 18 is a roomthat includes four walls, two doors, two windows, six electrical outletsand two light switches. Accordingly, automated construction robotprocess 34 may process 200 target area information 30 to locate suchwalls, doors, windows, electrical outlets and light switches within worksurface 18 and define work area coating plan 60.

Once work area coating plan 60 is defined, automated construction robotprocess 34 may generate 202 one or more coating plan instructions (e.g.,coating plan instructions 62) based, at least in part, upon work areacoating plan 60. Generally, coating plan instructions 62 may instructthe various portions of automated construction robot system 10 (e.g.,mobile base assembly 12, head assembly 16, arm assembly 20, wristassembly 22, rotation assembly 24 and machine vision system 26) to applycoating material 48 to whatever portions of work surface 18 need to becoated (e.g. bare drywall) while bot applying coating material 48 towhatever portions of work surface 18 should not be coated (e.g. doors,windows, electrical outlets, light switches). For example, if the firstwall within work surface 18 is 10′ high and 50′ long (with a 4′ wide by7′ high door located in the center of that first wall), the coating planinstructions (e.g., coating plan instructions 62) generated 202 mayinstruct the various portions of automated construction robot system 10(e.g., mobile base assembly 12, head assembly 16, arm assembly 20, wristassembly 22, rotation assembly 24 and machine vision system 26) to e.g.,applying coating material 48 from the floor to a height of 10′ for thefirst 23′ of the first wall . . . and then apply coating material 48from 8′ to 10′ for the next 4′ of the first wall . . . and then applycoating material 48 from the floor to a height of 10′ for the remaining23′ of the first wall.

Once coating plan instructions 62 are generated 202, automatedconstruction robot process 34 may manipulate 204 one or more of mobilebase assembly 12, head assembly 16 and arm assembly 20 to apply coatingmaterial 48 to work surface 18 via head assembly 12 based, at least inpart, upon one or more the coating plan instructions (e.g., coating planinstructions 62). For example, assume that head assembly 12 appliescoating material 48 in e.g., a 12″ wide stripe. Accordingly, automatedconstruction robot process 34 may manipulate 204 the various portions ofautomated construction robot system 10 (e.g., mobile base assembly 12,head assembly 16, arm assembly 20, wrist assembly 22, rotation assembly24 and machine vision system 26) to apply twenty-three 12″ wide verticalstripes of coating material 48 from floor level to 10′ high . . . andthen apply four 12″ wide vertical stripes of coating material 48 from 8′feet high to 10′ feet high . . . and then apply twenty-three 12″ widevertical stripes of coating material 48 from floor level to 10′ high.

Depending upon how automated construction robot process 34 isconfigured, automated construction robot process 34 may overlap thesestripes of coating material 48 to ensure consistent coverage.

Concept 3 (Automated Repair)

As discussed above, automated construction robot system 10 may includecomputational system 32 configured to execute automated constructionrobot process 34 and enable the interfacing with (and controlling of)one or more of mobile base assembly 12, head assembly 16, arm assembly20, wrist assembly 22, rotation assembly 24 and machine vision system26.

Further and as discussed above, automated construction robot system 10may include machine vision system 26 configured to scan a target area(e.g., target area 28) and generate target area information 30. Whenscanning target area 28 to generate target area information 30,automated construction robot process 34 may manipulate and maneuverautomated construction robot system 10 (generally) and mobile baseassembly 12 (specifically) so that machine vision system 26 may scan theentirety of work surface 18 to generate target area information 30.

Referring also to FIG. 5, automated construction robot process 34 may beconfigured to process 250 target area information 30 to identify anysurface defects (e.g., surface defect 64). As is known, when drywall isinstalled, the seams and interior corners are covered with a combinationof joint tape and drywall compound. And the fasteners that attach thedrywall to the underlying studs are fastened via drywall screws and/ordrywall nails, wherein the heads of such fasteners are also covered withdrywall compound. Further, exterior corners are covered with corner beadthat is fastened with either drywall screws or drywall nails, whereinthis corner bead and these fasteners are covered with drywall compound.

And while all surface defects are supposed to be addressed during thefinishing of the drywall, surface defects are routinely missed and needto be addressed prior to the application of coating material 48.Evidence of such surface defects (e.g., surface defect 64) may bememorialized (e.g., via stored images and/or videos) to document suchsurface defects and provide evidence of the same for reimbursementpurposes from third parties (e.g., the drywall installers).

Examples of such surface defects (e.g., surface defect 64) may includebut are not limited to one or more of:

-   -   A High Spot within the Work Surface 18: For example, a portion        of drywall compound that was applied to work surface 18 may have        been insufficiently sanded, resulting in a high spot within work        surface 18 that needs to be repaired.    -   A Low Spot within Work Surface 18: For example, an insufficient        quantity of drywall compound may have been applied to work        surface 18, resulting in a depression within work surface 18        that needs to be repaired.    -   A Crack within Work Surface 18: For example, a joint within the        drywall, or an interior/exterior corner may be been        insufficiently taped, resulting in a crack within work surface        18 that needs to be repaired.    -   A Hole within Work Surface 18: For example, damage to a piece of        drywall may have occurred, resulting in a hole within work        surface 18 that needs to be repaired.    -   A Protruding Screw within Work Surface 18: For example, a        drywall screw may have been insufficiently set within work        surface 18, resulting in a protruding screw head within work        surface 18 that needs to be repaired.    -   A Protruding Nail within Work Surface 18: For example, a drywall        nail may have been insufficiently set within work surface 18,        resulting in a protruding nail head within work surface 18 that        needs to be repaired.

Once a surface defect (e.g., surface defect 64) is identified, automatedconstruction robot process 34 may generate 252 one or more remedialinstructions (e.g., remedial instructions 66) based, at least in part,upon the surface defect (e.g., surface defect 64) identified. As wouldbe expected, these remedial instructions (e.g., remedial instructions66) may vary depending upon the type of surface defect (e.g., surfacedefect 64) identified.

Accordingly:

-   -   A High Spot within the Work Surface 18: For such a surface        defect, the remedial instructions (e.g., remedial instructions        66) generated 252 by automated construction robot process 34 may        include:        -   i. the sanding of work surface 18 to make the surface flat.    -   A Low Spot within Work Surface 18: For such a surface defect,        the remedial instructions (e.g., remedial instructions 66)        generated 252 by automated construction robot process 34 may        include:        -   i. the application of drywall compound to work surface 18 to            fill the depression; and        -   ii. the sanding of work surface 18 to make the surface flat.    -   A Crack within Work Surface 18: For such a surface defect, the        remedial instructions (e.g., remedial instructions 66) generated        252 by automated construction robot process 34 may include:        -   i. the application of drywall compound to work surface 18 to            fill the crack; and        -   ii. the sanding of work surface 18 to make the surface flat.    -   A Hole within Work Surface 18: For such a surface defect, the        remedial instructions (e.g., remedial instructions 66) generated        252 by automated construction robot process 34 may include:        -   i. the application of drywall compound to work surface 18 to            fill the hole; and        -   ii. the sanding of work surface 18 to make the surface flat.    -   A Protruding Screw within Work Surface 18: For such a surface        defect, the remedial instructions (e.g., remedial instructions        66) generated 252 by automated construction robot process 34 may        include:        -   i. the setting of the protruding screw;        -   ii. the application of drywall compound to work surface 18            to cover the screw head; and        -   iii. the sanding of work surface 18 to make the surface            flat.    -   A Protruding Nail within Work Surface 18: For such a surface        defect, the remedial instructions (e.g., remedial instructions        66) generated 252 by automated construction robot process 34 may        include:        -   i. the setting of the protruding nail;        -   ii. the application of drywall compound to work surface 18            to cover the nail head; and        -   iii. the sanding of work surface 18 to make the surface            flat.

Once the remedial instructions (e.g., remedial instructions 66) aregenerated 252, automated construction robot process 34 may manipulate254 one or more of mobile base assembly 12, head assembly 16 and armassembly 22 based, at least in part, upon the one or more remedialinstructions (e.g., remedial instructions 66). Generally, remedialinstructions 66 may instruct the various portions of automatedconstruction robot system 10 (e.g., mobile base assembly 12, headassembly 16, arm assembly 20, wrist assembly 22, rotation assembly 24and machine vision system 26) to perform the above-described remedialactions. For example, manipulating 254 one or more of mobile baseassembly 12, head assembly 16 and arm assembly 22 based, at least inpart, upon the one or more remedial instructions (e.g., remedialinstructions 66) may include one or more of:

-   -   Utilizing 256 head assembly 12 to sand the surface defect (e.g.,        surface defect 64) identified. For example, if head assembly 16        is configured to sand the surface defect (e.g., surface defect        64) included within work surface 18, head assembly 16 may be        utilized to perform such sanding functionality. In the event        that head assembly 16 affixed to arm assembly 20 is not capable        of sanding the surface defect (e.g., surface defect 64)        identified, a head assembly capable of performing such sanding        functionality may be selected by arm assembly 20 from plurality        of head assemblies 68.    -   Utilizing 258 head assembly 12 to apply joint compound to the        surface defect (e.g., surface defect 64) identified. For        example, if head assembly 16 is configured to apply joint        compound to the surface defect (e.g., surface defect 64)        included within work surface 18, head assembly 16 may be        utilized to perform such joint compound application        functionality. In the event that head assembly 16 affixed to arm        assembly 20 is not capable of applying joint compound to the        surface defect (e.g., surface defect 64) identified, a head        assembly capable of performing such joint compound application        functionality may be selected by arm assembly 20 from plurality        of head assemblies 68.    -   Utilizing 260 head assembly 12 to apply joint tape to the        surface defect (e.g., surface defect 64) identified. For        example, if head assembly 16 is configured to apply joint tape        to the surface defect (e.g., surface defect 64) included within        work surface 18, head assembly 16 may be utilized to perform        such joint tape application functionality. In the event that        head assembly 16 affixed to arm assembly 20 is not capable of        applying joint tape to the surface defect (e.g., surface defect        64) identified, a head assembly capable of performing such joint        tape application functionality may be selected by arm assembly        20 from plurality of head assemblies 68.    -   Utilizing 262 head assembly 12 to set a protruding drywall screw        within the surface defect (e.g., surface defect 64) identified.        For example, if head assembly 16 is configured to set the        protruding screw (e.g., surface defect 64) included within work        surface 18, head assembly 16 may be utilized to perform such        screw setting functionality. In the event that head assembly 16        affixed to arm assembly 20 is not capable of setting the        protruding screw (e.g., surface defect 64), a head assembly        capable of performing such screw setting functionality may be        selected by arm assembly 20 from plurality of head assemblies        68.    -   Utilizing 264 head assembly 12 to set a protruding nail within        the surface defect (e.g., surface defect 64) identified. For        example, if head assembly 16 is configured to set the protruding        nail (e.g., surface defect 64) included within work surface 18,        head assembly 16 may be utilized to perform such nail setting        functionality. In the event that head assembly 16 affixed to arm        assembly 20 is not capable of setting the protruding nail (e.g.,        surface defect 64), a head assembly capable of performing such        nail setting functionality may be selected by arm assembly 20        from plurality of head assemblies 68.

Concept 4 (Contact Detection)

As discussed above, automated construction robot system 10 may includecomputational system 32 configured to execute automated constructionrobot process 34 and enable the interfacing with (and controlling of)one or more of mobile base assembly 12, head assembly 16, arm assembly20, wrist assembly 22, rotation assembly 24 and machine vision system26.

As discussed above, when scanning target area 28 to generate target areainformation 30, automated construction robot process 34 may manipulateand maneuver automated construction robot system 10 (generally) andmobile base assembly 12 (specifically) so that machine vision system 26may scan the entirety of work surface 18 to generate target areainformation 30. Additionally and as discussed above, automatedconstruction robot process 34 may manipulate 100 one or more of mobilebase assembly 12, head assembly 16 and arm assembly 20 to apply coatingmaterial 48 to work surface 18 via head assembly 16. Further and asdiscussed above, automated construction robot process 34 may manipulate204 one or more of mobile base assembly 12, head assembly 16 and armassembly 20 to apply coating material 48 to work surface 18 via headassembly 12 based, at least in part, upon one or more the coating planinstructions (e.g., coating plan instructions 62). Additionally and asdiscussed above, automated construction robot process 34 may manipulate254 one or more of mobile base assembly 12, head assembly 16 and armassembly 22 based, at least in part, upon the one or more remedialinstructions (e.g., remedial instructions 66). Accordingly, it isforeseeable that one or more of mobile base assembly 12, head assembly16 and arm assembly 22 may make contact with (or impact) another object,examples of which may include but are not limited to a worker, a wall,and a piece of furniture.

Referring also to FIG. 6, when automated construction robot process 34is manipulating 300 (for any of the reasons discussed above) one or moreof mobile base assembly 12, head assembly 66 and arm assembly 22, ifcontact of mobile base assembly 12, head assembly 16 and/or arm assembly22 with an object (e.g., user 42) is detected 302, automatedconstruction robot process 34 may adjust 304 the manipulation of mobilebase assembly 12, head assembly 16 and/or arm assembly 22 in response tosensing such contact with the object (e.g., user 42).

As discussed above, examples of arm assembly 20 may include anyhydraulically-actuated, pneumatically-actuated, and/orelectrically-actuated computer-controllable arm assembly that may beconfigured to movably-couple head assembly 16 and mobile base assembly12. Accordingly, automated construction robot process 34 may beconfigured to monitor the hydraulic and/or pneumatic pressures withinarm assembly 20 (to detect 302 such a contact event). If electricallyactuated, automated construction robot process 34 may be configured tomonitor the electrical current within arm assembly 20 (to detect 302such a contact event). Additionally, touch sensitive bumper assemblies(e.g., bumper assembly 68) may be included within base assembly 12 andconfigured to detect 302 such a contact event.

When adjusting 304 the manipulation of mobile base assembly 12, headassembly 16 and/or arm assembly 22 in response to sensing such contactwith the object (e.g., user 42), automated construction robot process 34may effectuate one or more of the following operations:

-   -   Ceasing 306 movement of mobile base assembly 12, head assembly        16 and/or arm assembly 22 upon sensing such contact with the        object (e.g., user 42). For example and upon detecting 302 such        a contact event, automated construction robot process 34 may        immediately cease 306 any and all movement of mobile base        assembly 12, head assembly 16 and/or arm assembly 22.    -   Reversing 308 movement of mobile base assembly 12, head assembly        16 and/or arm assembly 22 upon sensing such contact with the        object (e.g., user 42). For example and upon detecting 302 such        a contact event, automated construction robot process 34 may        immediately reverse 308 any and all movement of mobile base        assembly 12, head assembly 16 and/or arm assembly 22.

Concept 6 (Edge Detection & Instruction)

As discussed above, automated construction robot system 10 may includecomputational system 32 configured to execute automated constructionrobot process 34 and enable the interfacing with (and controlling of)one or more of mobile base assembly 12, head assembly 16, arm assembly20, wrist assembly 22, rotation assembly 24 and machine vision system26.

Further and as discussed above, automated construction robot system 10may include machine vision system 26 configured to scan a target area(e.g., target area 28) and generate target area information 30. Whenscanning target area 28 to generate target area information 30,automated construction robot process 34 may manipulate and maneuverautomated construction robot system 10 (generally) and mobile baseassembly 12 (specifically) so that machine vision system 26 may scan theentirety of work surface 18 to generate target area information 30. Asdiscussed above and for this example, assume that work surface 18 is aroom that includes four walls, two doors, two windows, six electricaloutlets and two light switches.

Referring also to FIG. 7 and as discussed above, automated constructionrobot process 34 may be configured to manipulate 100 one or more ofmobile base assembly 12, head assembly 16 and arm assembly 20 to applycoating material 48 to work surface 18 via head assembly 16. Asdiscussed above, automated construction robot process 34 may process 200target area information 30 to locate e.g., walls, doors, windows,electrical outlets and light switches within work surface 18.

Accordingly, automated construction robot process 34 may process 350target area information 30 to generate one or more edge instructions(e.g., edge instructions 70). When processing 350 target areainformation 30 to generate one or more edge instructions (e.g., edgeinstructions 70), automated construction robot system 10 may effectuatethe following operations:

-   -   Identifying 352 an object within target area information 30 to        be avoided. For example, automated construction robot process 34        may process 350 target area information 30 to identify 352        objects (e.g., walls, doors, windows, electrical outlets and        light switches) to be avoided within work surface 18.    -   Processing 354 target area information 30 to generate one or        more edge instructions (e.g., edge instructions 70) for applying        coating material 48 to work surface 18 while avoiding the        identified object (e.g., walls, doors, windows, electrical        outlets and light switches) within work surface 18.

Automated construction robot process 34 may manipulate 356 the angle ofincidence of head assembly 16 with respect to work surface 18 based, atleast in part, upon the one or more edge instructions (e.g., edgeinstructions 70). As discussed above and referring again to FIG. 3, theangle of incidence (Θ) is the angle between a ray incident on a surface(e.g., work surface 18) and the line perpendicular to the surface at thepoint of incidence. Accordingly and when spray fan 150 is positionedperpendicular to work surface 18 (as shown in solid lines), the angle ofincidence (Θ) is 90 degrees. This may result in a decrease in thecrispness of edges 152, 154 of coating material 48 applied to worksurface 18 (thus allowing for the dithering of edges 152, 154 and ablending of the stripes of coating material 48). However, rotating sprayfan 150 about pivot point 156 included within wrist assembly 22 in aclockwise/counterclockwise direction may result in a decrease in theangle of incidence (Θ) and an increase in the crispness of: the edge 152(when rotating in a clockwise direction) and edge 154 (when rotating ina counterclockwise direction); thus allowing for coating material 48 tobe “cut in” around e.g., ceilings, floors, walls, doors, windows,switches, outlets, baseboard moldings, crown moldings, etc.

Accordingly and when manipulating 356 the angle of incidence (Θ) of headassembly 16 with respect to work surface 18 based, at least in part,upon the one or more edge instructions (e.g., edge instructions 70),automated construction robot process 34 effectuate one or more of thefollowing operations:

-   -   Rotating 358 head assembly 16 about an X-axis, which would        enable automated construction robot process 34 to e.g., switch        spray fan 150 between a horizontal orientation and a vertical        orientation.    -   Rotating 360 head assembly 16 about a Y-axis, which would enable        automated construction robot process 34 to e.g., adjust the        crispness of edges 152, 154 of coating material 48 applied to        work surface 18 when spray fan 150 is vertically orientated.    -   Rotating 362 head assembly 16 about a Z-axis, which would enable        automated construction robot process 34 to e.g., adjust the        crispness of edges 152, 154 of coating material 48 applied to        work surface 18 when spray fan 150 is horizontally orientated.

Therefore and when manipulating 356 the angle of incidence (Θ) of headassembly 16 with respect to work surface 18 based, at least in part,upon the one or more edge instructions (e.g., edge instructions 70),automated construction robot process 34 may effectuate one or more ofthe following operations:

-   -   decreasing 364 the angle of incidence (Θ) to increase the        crispness of an edge (e.g., edges 152 and/or edge 154) of        coating material 48 applied to work surface 18 (in the manner        described above).    -   increasing 366 the angle of incidence (Θ) to decrease the        crispness of an edge (e.g., edges 152 and/or edge 154) of        coating material 48 applied to work surface 18 (in the manner        described above).

Concept 7 (Non-Target Area Scanning)

As discussed above, automated construction robot system 10 may includecomputational system 32 configured to execute automated constructionrobot process 34 and enable the interfacing with (and controlling of)one or more of mobile base assembly 12, head assembly 16, arm assembly20, wrist assembly 22, rotation assembly 24 and machine vision system26.

Further and as discussed above, automated construction robot system 10may include machine vision system 26 configured to scan a target area(e.g., target area 28) and generate target area information 30. Whenscanning target area 28 to generate target area information 30,automated construction robot process 34 may manipulate and maneuverautomated construction robot system 10 (generally) and mobile baseassembly 12 (specifically) so that machine vision system 26 may scan theentirety of work surface 18 to generate target area information 30.

Additionally, machine vision system 26 may be configured to scan anon-target area (e.g., non-target area 72 and/or non-target area 74) andgenerate non-target area information 76. These non-target areas (e.g.,non-target area 72 and/or non-target area 74) may be positionedproximate target area 28. For example, non-target area 72 may bepositioned on the left of target area 28 and/or non-target area 74 maybe positioned on the right of target area 28. Accordingly and assumingthat coating material 48 is applied in a left-to-right fashion,non-target area 72 may be the area to which coating material 48 hasalready been applied and non-target area 74 may be the area to whichcoating material 48 has not yet been applied.

Referring also to FIG. 8 and as discussed above, automated constructionrobot process 34 may be configured to manipulate 100 one or more ofmobile base assembly 12, head assembly 16 and arm assembly 20 to applycoating material 48 to work surface 18 via head assembly 16.Additionally, automated construction robot process 34 may be configuredto process 400 the non-target area information (e.g., non-target areainformation 76) to generate one or more remedial instructions (e.g.,remedial instructions 66).

Further and as discussed above, automated construction robot process 34may manipulate 402 one or more of mobile base assembly 12, head assembly16 and arm assembly 22 based, at least in part, upon the one or moreremedial instructions (e.g., remedial instructions 66). Generally,remedial instructions 66 may instruct the various portions of automatedconstruction robot system 10 (e.g., mobile base assembly 12, headassembly 16, arm assembly 20, wrist assembly 22, rotation assembly 24and machine vision system 26) to perform various remedial actions (aswill be discussed below in greater detail).

As discussed above, non-target area 72 may include an area (within worksurface 18) to which coating material 48 has already been applied,wherein processing 400 non-target area information 76 to generate one ormore remedial instructions (e.g., remedial instructions 66) includesprocessing 404 non-target area information 76 to identify an appliedcoating material defect (e.g., coating defect 80) within non-target area72.

Examples of such applied coating material defects (e.g., coating defect80) may include but are not limited to one or more of:

-   -   No Coverage: An area to which coating material 48 was not        applied at all (resulting in bare drywall),    -   Light Coverage: An area to which coating material 48 was applied        too thinly (resulting in partially bare drywall).    -   Heavy Coverage: An area to which coating material 48 was applied        too heavily (which may have resulted in a run or a sag).

When manipulating 402 one or more of mobile base assembly 12, headassembly 16 and arm assembly 22 based, at least in part, upon the one ormore remedial instructions (e.g., remedial instructions 66), automatedconstruction robot process 34 may manipulate 406 one or more of mobilebase assembly 12, head assembly 16 and arm assembly 22 to address theidentified applied coating material defect (e.g., coating defect 80).

Examples of the manner in which automated construction robot process 34may manipulate 406 one or more of mobile base assembly 12, head assembly16 and arm assembly 22 to address the identified applied coatingmaterial defect (e.g., coating defect 80) may include but are notlimited to:

-   -   Utilizing head assembly 16 to apply coating material 48 to the        area to which coating material 48 was not applied at all.    -   Utilizing head assembly 16 to apply coating material 48 to the        area to which coating material 48 was applied too thinly.    -   Utilizing head assembly 16 to sand the run/sag and to apply        coating material 48 to the area that was sanded to address the        run/sag.

As discussed above, non-target area 74 may include an area (within workarea 18) to which coating material 48 has not yet been applied, whereinprocessing 400 non-target area information 76 to generate one or moreremedial instructions (e.g., remedial instructions 66) may includeprocessing 408 non-target area information 76 to identify a surfacedefect (e.g., surface defect 64) within non-target area 74.

As discussed above, examples of such surface defects (e.g., surfacedefect 64) may include but are not limited to one or more of:

-   -   A High Spot within the Work Surface 18: For example, a portion        of drywall compound that was applied to work surface 18 may have        been insufficiently sander, resulting in a high spot within work        surface 18 that needs to be repaired.    -   A Low Spot within Work Surface 18: For example, an insufficient        quantity of drywall compound may have been applied to work        surface 18, resulting in a depression within work surface 18        that needs to be repaired.    -   A Crack within Work Surface 18: For example, a joint within the        drywall, or an interior/exterior corner may be been        insufficiently taped, resulting in a crack within work surface        18 that needs to be repaired.    -   A Hole within Work Surface 18: For example, damage to a piece of        drywall may have occurred, resulting in a hole within work        surface 18 that needs to be repaired.    -   A Protruding Screw within Work Surface 18: For example, a        drywall screw may have been insufficiently set within work        surface 18, resulting in a protruding screw head within work        surface 18 that needs to be repaired.    -   A Protruding Nail within Work Surface 18: For example, a drywall        nail may have been insufficiently set within work surface 18,        resulting in a protruding nail head within work surface 18 that        needs to be repaired.

When manipulating 402 one or more of mobile base assembly 12, headassembly 16 and arm assembly 22 based, at least in part, upon the one ormore remedial instructions (e.g., remedial instructions 66), automatedconstruction robot process 34 may manipulate 410 one or more of mobilebase assembly 12, head assembly 16 and arm assembly 22 to address theidentified surface defect (e.g., surface defect 64).

Examples of the manner in which automated construction robot process 34may manipulate 410 one or more of mobile base assembly 12, head assembly16 and arm assembly 22 to address the identified surface defect (e.g.,surface defect 64) may include but are not limited to:.

-   -   Utilizing head assembly 16 to sand the surface defect (e.g.,        surface defect 64) identified.    -   Utilizing head assembly 16 to apply joint compound to the        surface defect (e.g., surface defect 64) identified.    -   Utilizing head assembly 16 to apply joint tape to the surface        defect (e.g., surface defect 64) identified.    -   Utilizing head assembly 16 to set a protruding drywall screw        within the surface defect (e.g., surface defect 64) identified.    -   Utilizing head assembly 16 to set a protruding nail within the        surface defect (e.g., surface defect 64) identified.

Concept 5 (Variable Duty Cycle Microcontroller)

As discussed above, automated construction robot system 10 may includecomputational system 32 configured to execute automated constructionrobot process 34 and enable the interfacing with (and controlling of)one or more of mobile base assembly 12, head assembly 16, arm assembly20, wrist assembly 22, rotation assembly 24 and machine vision system26. Further and as discussed above, automated construction robot process34 may be configured to manipulate 100 one or more of mobile baseassembly 12, head assembly 16 and arm assembly 20 to apply coatingmaterial 48 to work surface 18 via head assembly 16.

Referring also to FIG. 9 and as discussed above, supply line assembly 52may be utilized to receive coating material 48 from a coating supplysystem (e.g., internal chamber 50 or external container 54). Pumpassembly 162 may be utilized to pressurize coating material 48 (drawnfrom internal chamber 50/external container 54) and variable-duty-cyclemicrocontroller assembly 164 may be utilized to control 116 the volumeof coating material 48 and/or control 118 the pressure of coatingmaterial 48 provided to head assembly 16.

Variable-duty-cycle microcontroller 164 may include:

-   -   inlet port 450 configured to receive coating material 48 from        the coating supply system. Examples of such a coating supply        system may include an internal chamber (e.g., internal chamber        50) within which coating material 48 may be stored and/or an        external container (e.g., external container 54) that may        contain coating material 48. This coating supply system may be a        pressurized coating supply system (e.g., it may include pump        assembly 162) in order to provide coating material 48 to inlet        port 450 of variable-duty-cycle microcontroller 164.    -   outlet port 452 configured to provide a regulated quantity of        coating material 48 to head assembly 16.    -   coating material regulation system 454 configured to control the        passage of coating material 48 from inlet port 450 to outlet        port 452, wherein coating material regulation system 454 may be        configured to process a variable-duty-cycle control signal        (e.g., control signal 456) provided by computational system 32        and regulate the quantity of coating material 48 applied to work        surface 18 via head assembly 16. As will be discussed below in        greater detail, the variable duty cycle control signal (e.g.,        control signal 456) may be is configured to have an increased        duty cycle (e.g., control signal 456A) when an increased        quantity of coating material 48 is needed at outlet port 452.        Conversely, the variable duty cycle control signal (e.g.,        control signal 456) may be configured to have a decreased duty        cycle (e.g., control signal 456B) when a decreased quantity of        coating material 48 is needed at outlet port 452.

Coating material regulation system 454 may include one or more valveassemblies (e.g., valve assemblies 458) configured to selectivelyfluidly-couple inlet port 450 and outlet port 452. The one or more valveassemblies (e.g., valve assemblies 458) may be configured to beselectively energized and deenergized based, at least in part, upon thevariable-duty-cycle control signal (e.g., control signal 456). Forexample, automated construction robot process 34 may be configured tomonitor the pressure of coating material 48 being applied to headassembly 16.

In the event that the pressure of coating material 48 being applied tohead assembly 16 is too high, the variable-duty-cycle control signal(e.g., control signal 456) may be adjusted to regulate the pressure ofthe coating material 48 being applied to head assembly 16 downward. Forexample, the variable duty cycle control signal (e.g., control signal456) may be adjusted to have a decreased duty cycle (e.g., controlsignal 506B) when a decreased quantity of coating material 48 is neededat outlet port 452.

Conversely, in the event that the pressure of the coating material 48being applied to head assembly 16 is too low, the variable-duty-cyclecontrol signal (e.g., control signal 456) may be adjusted to regulatethe pressure of coating material 48 being applied to head assembly 16upward. For example, the variable duty cycle control signal (e.g.,control signal 456) may be adjusted to have an increased duty cycle(e.g., control signal 456A) when an increased quantity of coatingmaterial 48 is needed at outlet port 504.

Accordingly, selectively energizing and deenergizing the one or morevalve assemblies (e.g., valve assemblies 458) based, at least in part,upon the variable-duty-cycle control signal (e.g., control signal 456)may enable precise control of the quantity of coating material 48provided to outlet port 452.

Multiple Robots

As discussed above, automated construction robot system 10 may includecomputational system 32 configured to execute automated constructionrobot process 34 and enable the interfacing with (and controlling of)one or more of mobile base assembly 12, head assembly 16, arm assembly20, wrist assembly 22, rotation assembly 24 and machine vision system26.

Further and as discussed above, automated construction robot system 10may include machine vision system 26 configured to scan a target area(e.g., target area 28) and generate target area information 30.Additionally, machine vision system 26 may be configured to scan anon-target area (e.g., non-target area 72 and/or non-target area 74) andgenerate non-target area information 76.

While the scanning of target area 28 and non-target area 72, 74 isdiscussed above as being accomplished via a single automatedconstruction robot system, this is for illustrative purposes only and isnot intended to be a limitation of this disclosure, as otherconfigurations are possible and are considered to be within the scope ofthis disclosure. For example, automated construction robot system 10 mayinclude a plurality of automated construction robots, namely a primaryconstruction robot (e.g., automated construction robot system 10); and ascout construction robot (e.g., scanning robot system 80). In such aconfiguration, the scout construction robot (e.g., scanning robot system80) may be configured to effectuate the above-described scanningfunctionality (e.g., the scanning of target area 28 and/or non-targetarea 72, 74) to generate target area information 30 and/or non-targetarea information 76.

As discussed above, automated construction robot system 10 may beconfigured to be wirelessly coupled to access point 44 via wirelesscommunication channel 46 established between automated constructionrobot system 10 and access point 44. Additionally, scout constructionrobot (e.g., scanning robot system 80) may be configured to bewirelessly coupled to access point 44 via a wireless communicationchannel established between scanning robot system 80 and access point44. Accordingly, network 40 and access point 44 may be configured toallow automated construction robot system 10 and scanning robot system80 to communicate, thus enabling the above-described scanningoperations.

General

As will be appreciated by one skilled in the art, the present disclosuremay be embodied as a method, a system, or a computer program product.Accordingly, the present disclosure may take the form of an entirelyhardware embodiment, an entirely software embodiment (includingfirmware, resident software, micro-code, etc.) or an embodimentcombining software and hardware aspects that may all generally bereferred to herein as a “circuit,” “module” or “system.” Furthermore,the present disclosure may take the form of a computer program producton a computer-usable storage medium having computer-usable program codeembodied in the medium.

Any suitable computer usable or computer readable medium may beutilized. The computer-usable or computer-readable medium may be, forexample but not limited to, an electronic, magnetic, optical,electromagnetic, infrared, or semiconductor system, apparatus, device,or propagation medium. More specific examples (a non-exhaustive list) ofthe computer-readable medium may include the following: an electricalconnection having one or more wires, a portable computer diskette, ahard disk, a random access memory (RAM), a read-only memory (ROM), anerasable programmable read-only memory (EPROM or Flash memory), anoptical fiber, a portable compact disc read-only memory (CD-ROM), anoptical storage device, a transmission media such as those supportingthe Internet or an intranet, or a magnetic storage device. Thecomputer-usable or computer-readable medium may also be paper or anothersuitable medium upon which the program is printed, as the program can beelectronically captured, via, for instance, optical scanning of thepaper or other medium, then compiled, interpreted, or otherwiseprocessed in a suitable manner, if necessary, and then stored in acomputer memory. In the context of this document, a computer-usable orcomputer-readable medium may be any medium that can contain, store,communicate, propagate, or transport the program for use by or inconnection with the instruction execution system, apparatus, or device.The computer-usable medium may include a propagated data signal with thecomputer-usable program code embodied therewith, either in baseband oras part of a carrier wave. The computer usable program code may betransmitted using any appropriate medium, including but not limited tothe Internet, wireline, optical fiber cable, RF, etc.

Computer program code for carrying out operations of the presentdisclosure may be written in an object oriented programming languagesuch as Java, Smalltalk, C++ or the like. However, the computer programcode for carrying out operations of the present disclosure may also bewritten in conventional procedural programming languages, such as the“C” programming language or similar programming languages. The programcode may execute entirely on the user's computer, partly on the user'scomputer, as a stand-alone software package, partly on the user'scomputer and partly on a remote computer or entirely on the remotecomputer or server. In the latter scenario, the remote computer may beconnected to the user's computer through a local area network/a widearea network/the Internet (e.g., network 14).

The present disclosure is described with reference to flowchartillustrations and/or block diagrams of methods, apparatus (systems) andcomputer program products according to embodiments of the disclosure. Itwill be understood that each block of the flowchart illustrations and/orblock diagrams, and combinations of blocks in the flowchartillustrations and/or block diagrams, may be implemented by computerprogram instructions. These computer program instructions may beprovided to a processor of a general purpose computer/special purposecomputer/other programmable data processing apparatus, such that theinstructions, which execute via the processor of the computer or otherprogrammable data processing apparatus, create means for implementingthe functions/acts specified in the flowchart and/or block diagram blockor blocks.

These computer program instructions may also be stored in acomputer-readable memory that may direct a computer or otherprogrammable data processing apparatus to function in a particularmanner, such that the instructions stored in the computer-readablememory produce an article of manufacture including instruction meanswhich implement the function/act specified in the flowchart and/or blockdiagram block or blocks.

The computer program instructions may also be loaded onto a computer orother programmable data processing apparatus to cause a series ofoperational steps to be performed on the computer or other programmableapparatus to produce a computer-implemented process such that theinstructions which execute on the computer or other programmableapparatus provide steps for implementing the functions/acts specified inthe flowchart and/or block diagram block or blocks.

The flowcharts and block diagrams in the figures may illustrate thearchitecture, functionality, and operation of possible implementationsof systems, methods and computer program products according to variousembodiments of the present disclosure. In this regard, each block in theflowchart or block diagrams may represent a module, segment, or portionof code, which comprises one or more executable instructions forimplementing the specified logical function(s). It should also be notedthat, in some alternative implementations, the functions noted in theblock may occur out of the order noted in the figures. For example, twoblocks shown in succession may, in fact, be executed substantiallyconcurrently, or the blocks may sometimes be executed in the reverseorder, depending upon the functionality involved. It will also be notedthat each block of the block diagrams and/or flowchart illustrations,and combinations of blocks in the block diagrams and/or flowchartillustrations, may be implemented by special purpose hardware-basedsystems that perform the specified functions or acts, or combinations ofspecial purpose hardware and computer instructions.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the disclosure.As used herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of allmeans or step plus function elements in the claims below are intended toinclude any structure, material, or act for performing the function incombination with other claimed elements as specifically claimed. Thedescription of the present disclosure has been presented for purposes ofillustration and description, but is not intended to be exhaustive orlimited to the disclosure in the form disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the disclosure. Theembodiment was chosen and described in order to best explain theprinciples of the disclosure and the practical application, and toenable others of ordinary skill in the art to understand the disclosurefor various embodiments with various modifications as are suited to theparticular use contemplated.

A number of implementations have been described. Having thus describedthe disclosure of the present application in detail and by reference toembodiments thereof, it will be apparent that modifications andvariations are possible without departing from the scope of thedisclosure defined in the appended claims.

What is claimed is:
 1. An automated construction robot systemcomprising: a mobile base assembly configured to be displaceable withinthe work area; a head assembly configured to process a work surface; anarm assembly configured to moveably-couple the head assembly and themobile base assembly and controllably-displace the head assembly withrespect to the work surface; a machine vision system configured to scana target area and generate target area information; and a computationalsystem configured to: process the target area information to identify asurface defect, generate one or more remedial instructions based, atleast in part, upon the surface defect identified, and manipulate one ormore of the mobile base assembly, the head assembly and the arm assemblybased, at least in part, upon the one or more remedial instructions. 2.The automated construction robot system of claim 1 wherein manipulatingone or more of the mobile base assembly, the head assembly and the armassembly based, at least in part, upon the one or more remedialinstructions includes one or more of: utilizing the head assembly tosand the surface defect identified; utilizing the head assembly to applyjoint compound to the surface defect identified; utilizing the headassembly to apply joint tape to the surface defect identified; utilizingthe head assembly to set a protruding drywall screw within the surfacedefect identified; and utilizing the head assembly to set a protrudingnail within the surface defect identified.
 3. The automated constructionrobot system of claim 1 wherein the surface defect identified includesone or more of: a high spot within the work surface; a low spot withinthe work surface; a crack within the work surface; a hole within thework surface; a protruding screw within the work surface; and aprotruding nail within the work surface.
 4. The automated constructionrobot system of claim 1 wherein the computational system is furtherconfigured to: manipulate one or more of the mobile base assembly, thehead assembly and the arm assembly to apply a coating material to thework surface via the head assembly.
 5. The automated construction robotsystem of claim 4 wherein manipulating one or more of the mobile baseassembly, the head assembly and the arm assembly to apply a coatingmaterial to the work surface via the head assembly includes one or moreof: controlling the movement of the mobile base assembly within a workarea; extending/retracting the arm assembly with respect to the mobilebase assembly; controlling the location of the head assembly withrespect to the work surface and/or the mobile base assembly; controllingthe velocity of the head assembly with respect to the work surfaceand/or the mobile base assembly; rotating the head assembly with respectto the work surface; and controlling the angle of incidence of the headassembly with respect to the work surface.
 6. The automated constructionrobot system of claim 4 wherein manipulating one or more of the mobilebase assembly, the head assembly and the arm assembly to apply a coatingmaterial to the work surface via the head assembly includes one or moreof: controlling a spray fan width of the coating material applied to thework surface via the head assembly; controlling the volume of thecoating material provided to the head assembly; and controlling thepressure of the coating material provided to the head assembly.
 7. Theautomated construction robot system of claim 1 wherein the arm assemblyincludes: a wrist assembly configured to enable the rotation of the headassembly with respect to the arm assembly.
 8. The automated constructionrobot system of claim 1 wherein the arm assembly includes: a rotationassembly configured to enable the rotation of the arm assembly withrespect to the mobile base assembly.
 9. The automated construction robotsystem of claim 1 wherein the automated construction robot systemincludes a plurality of automated construction robots.
 10. The automatedconstruction robot system of claim 9 wherein the plurality of automatedconstruction robots includes: a primary construction robot; and a scoutconstruction robot.
 11. The automated construction robot system of claim10 wherein the scout construction robot is configured to scan the targetarea and generate the target area information.
 12. Acomputer-implemented method, executed on an automated construction robotsystem, comprising: processing target area information to identify asurface defect; generating one or more remedial instructions based, atleast in part, upon the surface defect identified; and manipulating oneor more of a mobile base assembly, a head assembly and an arm assemblybased, at least in part, upon the one or more remedial instructions;wherein: the mobile base assembly is configured to be displaceablewithin a work area, the head assembly is configured to process the worksurface, and the arm assembly is configured to moveably-couple the headassembly and the mobile base assembly and controllably-displace the headassembly with respect to the work surface.
 13. The computer-implementedmethod of claim 12 wherein manipulating one or more of the mobile baseassembly, the head assembly and the arm assembly based, at least inpart, upon the one or more remedial instructions includes one or moreof: utilizing the head assembly to sand the surface defect identified;utilizing the head assembly to apply joint compound to the surfacedefect identified; utilizing the head assembly to apply joint tape tothe surface defect identified; utilizing the head assembly to set aprotruding drywall screw within the surface defect identified; andutilizing the head assembly to set a protruding nail within the surfacedefect identified.
 14. The computer-implemented method of claim 12wherein the surface defect identified includes one or more of: a highspot within the work surface; a low spot within the work surface; acrack within the work surface; a hole within the work surface; aprotruding screw within the work surface; and a protruding nail withinthe work surface.
 15. The computer-implemented method of claim 12wherein the arm assembly includes: a wrist assembly configured to enablethe rotation of the head assembly with respect to the arm assembly. 16.The computer-implemented method of claim 12 wherein the arm assemblyincludes: a rotation assembly configured to enable the rotation of thearm assembly with respect to the mobile base assembly.
 17. A computerprogram product residing on a computer readable medium having aplurality of instructions stored thereon which, when executed by anautomated construction robot system, cause the automated constructionrobot system to perform operations comprising: processing target areainformation to identify a surface defect; generating one or moreremedial instructions based, at least in part, upon the surface defectidentified; and manipulating one or more of a mobile base assembly, ahead assembly and an arm assembly based, at least in part, upon the oneor more remedial instructions; wherein: the mobile base assembly isconfigured to be displaceable within a work area, the head assembly isconfigured to process the work surface, and the arm assembly isconfigured to moveably-couple the head assembly and the mobile baseassembly and controllably-displace the head assembly with respect to thework surface.
 18. The computer program product of claim 17 whereinmanipulating one or more of the mobile base assembly, the head assemblyand the arm assembly based, at least in part, upon the one or moreremedial instructions includes one or more of: utilizing the headassembly to sand the surface defect identified; utilizing the headassembly to apply joint compound to the surface defect identified;utilizing the head assembly to apply joint tape to the surface defectidentified; utilizing the head assembly to set a protruding drywallscrew within the surface defect identified; and utilizing the headassembly to set a protruding nail within the surface defect identified.19. The computer program product of claim 17 wherein the surface defectidentified includes one or more of: a high spot within the work surface;a low spot within the work surface; a crack within the work surface; ahole within the work surface; a protruding screw within the worksurface; and a protruding nail within the work surface.
 20. The computerprogram product of claim 17 wherein the arm assembly includes: a wristassembly configured to enable the rotation of the head assembly withrespect to the arm assembly.
 21. The computer program product of claim17 wherein the arm assembly includes: a rotation assembly configured toenable the rotation of the arm assembly with respect to the mobile baseassembly.